#3 Empty Capsule Filler - filling medical gelcap

Last crawled date: 4 years, 2 months ago

Size 3 Capsule Filler - filling medical gelcap
WHAT IS IT?
It's a device to speed up the filling of empty gelcaps with powdered supplements that you want to be able to swallow. (making your own capsules) I created this because my body typically needs less medicine than is sold in health food store capsules, so I needed to find my own dosage then find the capsule size that will store the amount of powder I need for my dose.
I use these most frequently to make capsules (for Targeted Amino Acid Therapy) so I've honed it a lot to get it where I want it.
I've learned to get the dosage fairly precise +/- .010g and can tweak the dosage by choosing to either: lightly fill the capsules just till full, or filling then tapping the whole rig 1 or more times (to get the powder to compact slightly) then fill again, or not caring and just packing the capsules all the way using the packer (compactor) to press the powder in tight and keep adding more till absolutely full.
I've created identical units for these four capsule sizes:
size 1- https://www.thingiverse.com/thing:4078171
size 3- https://www.thingiverse.com/thing:4079394
size 4- https://www.thingiverse.com/thing:4079607
size 5- https://www.thingiverse.com/thing:4079997
This is a remix of:https://www.thingiverse.com/thing:2349276
PARTS:
There are 6 parts:
1- Hole test (optional)
This is a test part to see what % you need to print the part at to match the variability in your filament's shrinkage rate and in the capsule sizes for the batch you have.
I bring this into my slicer at 100%, then duplicate it... and make one at 96%, 98%, 102% and 105%... then I line them all up so they just slightly overlap and create 1 part from this test file small to large. I print, then test with my empty capsules. I ideally want the capsule to slightly grab in the hole, not fall through and not get wedged.
(there is variability in most printing diameters so not all the holes will be identical, find a good balance.)
2- Capsule Filler
This is the main part where you insert the bottom half of the capsules to be filled. Print this at whatever % you found best when you printed the hole test part.
Depending on your slicer settings or filament there may be more or less variability in your hole sizes on the final print (some perfect, some to small) Another option is to find a drill bit that is the perfect size for the capsule and clean up the holes that seem too snug. You can also use this and skip the size test... just print at 100% and drill the holes to the exact size.
3- Extended base BEST!
4- Short base (optional)
The capsule filler slides into the base to hold it in place so the capsules are the correct distance from the base and that you can't accidentally lift the capsule filler up and dump your capsules. It also allows you to pick up the whole unit and tap it on a counter to compact the material slightly to control dosing.
[note: the bases for size 3 & 4 are the same. If you use both sizes, print the base only once, both fillers will work with this base]
Whatever % you used to print the capsule filler above, use the same % to print this part.
There are two versions of the base:
a- Extended Base (suggested) with attached receiver tray - where you set the capsule filler to put the cap lids on so it keeps the powder contained.
b-Base (short), open with no receiver tray -you slide out the capsule filler onto a counter surface to apply the cap lids... and may spill some powder on counter.
5- Packer (optional)
Once you fill the capsules with powder, if you want them to have the maximum amount in them, press the packer into the full capsules to compact the powder, then refill powder. Repeat until powder no longer packs down. (The part works best when orientated with the rounded corners facing the open tray).
The packer will need supports. The best print I've gotten is from laying the part on edge, with pins sticking out sideways.
6- Paddle
This is the scraper you use to move the powder over the holes to make sure all the capsules are evenly filled.
FILAMENT/FLOW:
Select a filament that gives you a nice flow with smooth surfaces (or tweak your temp & flow rates) to get the surfaces as smooth as you can. The smoother your top surfaces are, the less chance of whatever powder you're using to stick in the tiny spaces between lines.
Some filaments will naturally do a better job... some can be a bitch to calibrate and get the holes nice. Use your most cooperative filament :)
SLICER SETTINGS: (Cura)
Speed: use whatever speed you can get accurate parts from, slow down if needed. I used 60 (first layers 20)
Layer Height: .28 (or finer if you like)
Rafts: No! (we want a smooth surface on bottom)
Supports: (only for packer)
Infill: 15-20% (I like cubic)
IRONING: Yes!
For the base ironing is OPTIMAL - useful to get a nice smooth surface (so powder doesn't stick in the ridges of the plastic) I'm using:
enable ironing [ON]
Iron only highest layer [OFF]
ironing pattern: zig zag
ironing line spacing: 0.1mm
ironing flow: 1% (this will vary based on your filament... this may be closer to 10% for you)
ironing inset: 0.2mm
ironing speed: 23.33
Adaptive Layers: (optional)
To smooth out some of the curves you can use adaptive layers in Cura. But it doesn't really add to the functionality, so you can skip if you want.
Use adaptive layers [ON]
Adaptive Layers Maximum Variation: 0.04mm
Adaptive Layers Variation Step Size: 0.04mm
Adaptive Layers Threshold: 100.0
SOURCE FILES:https://www.tinkercad.com/things/6CclH1blfVb-3-filler-assembly-final